Pvc/polyester binder for products

ABSTRACT

A product is provided having a biobased component where the biobased component includes recycle polyester resin and the recycle polyester resin includes polyethylene terephthalate, polybutylene, or polypropylene terephthalate. The biobased component includes a polyester resin where the polyester resin is the co-reaction product of an aliphatic polyester having renewable components and a recycle polyester resin. Included is a composition having a filler and a polymeric binder. The filler includes inorganic biobased filler or recycle thermoset resin based filler.

CROSS-REFERENCE TO RELATED APPLICATION

This application is claiming the benefit of prior-filed nonprovisionalapplication Ser. No. 11/541,976, filed Oct. 2, 2006, and entitled“PVC/POLYESTER BINDER FOR FLOORING”, the disclosure of which isincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to the field of surfacecoverings. More particularly, the present invention relates to surfacecoverings having a polymeric binder comprising homo-polymer PVC resinand thermoplastic, high molecular weight polyester resin. The polyesterresin of the invention comprises renewable components and can beamorphous or crystalline in nature. A product is described thatcomprises a renewable or recycle content that classifies the product forpoints under the LEED system for commercial products.

BACKGROUND OF THE INVENTION

Vinyl flooring is a major category of product for residential andcommercial construction. Polyvinyl chloride (PVC) is the major polymericmaterial that functions as binder and imparts desired physicalproperties of vinyl flooring. Vinyl flooring product structures mayinclude single layer products such as vinyl composition tile (VCT) andsheet and tile structures containing more than one layer. In someproducts, a high performance coating is utilized on the surface of thestructure comprising PVC to impart improved scratch resistance.

Most layers of vinyl flooring products also include a plasticizermaterial to soften and allow processing of the PVC resin. Some liquidpolyesters have found limited utility as plasticizers for PVC resins.Plasticizers contribute little to the strength properties of the finalPVC layer after processing.

Typically, low molecular weight, liquid esters of aromatic acids such asphthalates and benzoates are utilized as plasticizers in flooringcompositions. These plasticizers have enough volatility to be consideredVolatile Organic Components in some clean air environments. Thephthalate esters in particular are also suspect from anenvironmental/health perspective due to their possible biologicalactivity.

One high volume, commercial vinyl tile product, VCT, typically comprisesplasticizer and a blend of PVC homo-polymer and PVC co-polymer, e.g.vinyl acetate, as binders in the composition. The vinyl acetateco-polymer allows the composition to be melt when mixed in the lowintensity mixers typically used in VCT manufacturing. The PVCcompositions are typically heated to less than about 150° C. in tileprocesses utilizing such equipment. Another issue is that the vinylacetate PVC co-polymer is currently in tight supply.

Recently, the US Green Building Council has established the LEED(Leadership in Energy and Environmental Design) system for scoringpoints for new commercial construction (Table 1). Under the LEED system,flooring can be used to obtain points if it contains 10% by weight of ormore of post-industrial recycle material.

TABLE 1 LEED System For New Commercial Construction Rating Rating SystemLEED-NC Version 2.1 System LEED-EB Version 2.0 MR Credit 5% wt = (post-MR Credit 10% (Post- 4.1 consumer + ½ post- 2.1 Consumer materials), 1Point industrial) 1 Point or MR Credit 10% wt = (post- 20% (Post- 4.2consumer + ½ post- Industrial materials) 1 Point industrial) MR Credit5% wt = (rapidly MR Credit 50% (Rapidly 6 renewable building 2.5renewable materials) 1 Point materials and products) 1 Point

NC: New Construction; EB: Existing Building; Minimum % wt for eachpoint. The % for both NC and EB is weight percent. For NC 1 point isgranted for at least 5% wt of the total of post-consumer and ½post-industrial. A second point is granted for at least 10% wt of thetotal of post-consumer and ½ post-industrial. An additional point isgranted for at least 5% wt of rapidly renewable building materials andproducts. For EB 1 point is granted for at least 10% wt post-consumermaterials. A second point is granted for at least 20% wt ofpost-industrial materials. An additional point is granted for at least50% wt of rapidly renewable materials.

There has been renewed market interest in giving preference to “greener”flooring products based upon this LEED System. The use of renewablematerials is of high interest.

There remains a need to develop “greener” flooring products based uponexisting product structures/processes, and available recycle orrenewable materials. There also is a need to find a binder system forvinyl flooring products that eliminates low molecular weightplasticizers and the need for vinyl acetate co-polymers of PVC in somevinyl tile manufacturing processes.

A product having a biobased component, where the biobased componentincludes recycle polyester resin would be desirable in the art.

BRIEF DESCRIPTION OF THE INVENTION

In an exemplary embodiment, a product having a biobased component, wherethe biobased component includes recycle polyester resin. The recyclepolyester resin includes polyethylene terephthalate, polybutyleneterephthalate, or polypropylene terephthalate.

In another exemplary embodiment, a product having a biobased componentwhere the biobased component includes a polyester resin. The polyesterresin is the co-reaction product of an aliphatic polyester havingrenewable components and a recycle polyester resin. The recyclepolyester resin is aromatic based and has a biobased content of at leastabout 5% by weight.

In another exemplary embodiment, a composition having a filler and apolymeric binder where the filler includes biobased inorganic filler orrecycle thermoset resin based filler. The polymeric binder includes abiobased component and the biobased component includes recycle polyesterresin having a biobased content of at least about 5% by weight.

A product is provided having at least one layer including a polymericbinder comprising a homo-polymer PVC resin and either a high molecularweight thermoplastic polyester resin or a highly viscous polyesterresin. In some embodiments, the thermoplastic polyester resin or thehighly viscous polyester resin has a number average molecular weight(Mn) of at least 5,000. In other embodiments the polyester resin or thehighly viscous polyester resin has a molecular weight (Mn) of at least10,000.

In some embodiments, the highly viscous polyester resin has a viscosityof at least 15,000 cps at 100° F. using a Brookfield viscosimeter. Inother embodiments the highly viscous polyester resin has a viscosity ofat least 35,000 cps at 100° F. using a Brookfield viscometer.

The polyester resin may be biodegradable, and/or may contain renewablecomponents. In one embodiment, the polyester resin comprises at least50% by weight of renewable components. In another embodiment, thepolyester resin comprises greater than 80% by weight of renewablecomponents. In yet another embodiment, the polyester resin may compriseessentially 100% by weight of renewable components. Additionally, insome embodiments the polyester resin comprises essentially 100% byweight of renewable and recycle components.

The polyesters may comprise aliphatic diacid and aliphatic diolcomponents. In one embodiment, these components preferably come fromrenewable sources. In other embodiments, the polyester can comprisearomatic diacids and aliphatic diol components. In other embodiments,the polyester can comprise aliphatic diacids, aromatic diacid, andaliphatic diol components. The polyesters can be amorphous orcrystalline/semi-crystalline in nature. In one embodiment the polyesteris amorphous having a Tg at or below about 25° C. In other embodiments,the polyester may be crystalline and have a Tg at or below about 25° C.and a melt temperature (Tm) above about 25° C. In some embodiments, theTm is above about 25° C. but below about 200° C. In yet anotherembodiment, the polyester may comprise branching.

In another embodiment, the polyester comprises the co-reaction productof a aliphatic high molecular weight polyester comprising renewablecomponents and a recycle polyester resin. In some embodiments, therecycle polyester resin is aromatic based and includes polyethyleneterephthalate, polybutylene terephthalate, and polypropyleneterephthalate.

In one embodiment, the layer comprising homopolymer PVC and highmolecular weight polyester further comprises a recycle or renewablefiller. The product of the invention can be in the form of a sheet ortile structure. In some embodiments, the product is essentially a singlelayer structure, such as a VCT. In one embodiment, the product having alayer including a binder comprising homo-polymer PVC resin andthermoplastic, high molecular weight polyester resin also has sufficientrecycle or renewable content to qualify for at least one point under theLEED system.

In another embodiment, a composition is provided including filler and apolymeric binder comprising at least one PVC homo-polymer resin and atleast one thermoplastic, high molecular weight polyester resins havingat least one renewable component, wherein the composition may be meltmixed in a low intensity mixer and processed into a layer.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Provided is a product having a biobased component where the biobasedcomponent includes recycle polyester resin. The recycle polyester resinincludes polyethylene terephthalate, polybutylene terephthalate, orpolypropylene terephthalate. The recycle polyester resin has a biobasedcontent of at least about 5% by weight.

In one embodiment, the biobased component includes a polyester resinwhere the polyester resin is the co-reaction product of an aliphaticpolyester having renewable components and a recycle polyester resin. Therecycle polyester resin is aromatic based and includes polyethyleneterephthalate, polybutylene terephthalate, or polypropyleneterephthalate. The polyester resin has a biobased content of at leastabout 5% by weight.

In another embodiment, a composition is provided having a filler and apolymeric binder. The filler includes inorganic biobased filler orrecycle thermoset resin based filler. The polymeric binder includes abiobased component where the biobased component includes a recyclepolyester resin having a biobased content of at least about 5% byweight.

This invention includes a product having at least one layer including apolymeric binder comprising a homo-polymer PVC resin and athermoplastic, high molecular weight polyester resin, wherein thepolyester resin comprises at least one renewable component. The productcan comprise sheet or tile products. The layer in these structures maybe solid or foamed, and filled or unfilled. In some embodiments thelayer comprises a transparent wear layer or wear layer component.

One particular well known example of a prior art flooring product isvinyl composition tile (VCT), as described by ASTM Specification1066-04. While the present invention is intended for use in such tile,as the Specification and Examples describe, it will be obvious to oneskilled in the art that the invention is also applicable to variousother types of flooring, including tile products such as Type III solidvinyl tile, surface applied tile, and to sheet flooring products.

In one embodiment, the at least one layer comprises consolidated chipsor particles having a binder comprising a homo-polymer PVC and athermoplastic, high molecular weight polyester resin. In anotherembodiment, the layer is a homogeneous, melt processed layer having abinder comprising a homo-polymer PVC and a thermoplastic, high molecularweight polyester resin.

In one embodiment, the at least one layer comprises consolidated chipsor particles having a binder comprising a homo-polymer PVC and a highlyviscous polyester resin. In another embodiment, the layer is ahomogeneous, melt processed layer having a binder comprising ahomo-polymer PVC and a highly viscous polyester resin.

Unless the layer is transparent, it typically comprises a filler inaddition to the polymeric binder. Limestone, talc, or other minerals areutilized as filler in PVC flooring. Interest in using recycle materialsas fillers has increased due to “green” issues. Such recycle orrenewable filler materials include those obtained from wood or plants.These include pecan shells, wood flour, saw dust, walnut shells, ricehulls, corn cob grit, and others. Additionally, ground shells fromanimals such as clams, coral, etc. are renewable inorganic fillers. Suchrenewable fillers contain biobased carbon in the form of carbonates.These can be considered post-industrial or renewable materials under theLEED System. Mineral fillers generated from post-industrial processesinclude limestone, quartz, ceramic powders, glass, fly ash, and concretepowder.

Recycle thermoset resin based fillers can also be employed. For example,powders produced by grinding thermoset polyester materials, such asproducts made from bulk molding compounds (BMC) or sheet moldingcompounds (SMC) can be post-industrial, as well as post-consumermaterials. Another thermoset material of interest is recycled fillersmade from Urea Formaldehyde thermoset resins. Depending upon the source,these materials can also be post-industrial or post-consumer. Anotherexample includes ground, cured (cross-linked) rubber materials such asused in tires. These rubbers materials can be based on natural orsynthetic rubbers, polyurethanes, or other well known thermoset rubbercompositions.

Additionally, recycle thermoplastic resin based materials may beemployed as fillers if they are incompatible with the PVC/polyesterresin binder. For example, polyethylene, polypropylene, polystyrene,polycarbonate, acrylonitrile butadiene styrene, and thermoplasticrubbers maybe incompatible with the PVC/high molecular weight polyesterbinder. Such materials, if added as particulate will essentiallyfunction as fillers in these compositions. If the recycled thermoplasticresin is compatible with the binder, it may function as a binder and notas a filler in the composition. Compatibility may be dependent upon theprocessing conditions employed. Depending upon the source, thesematerials can be post-industrial or post-consumer.

In one embodiment, the layer comprises a recycle or renewable filler inaddition to the PVC/high molecular weight polyester binder or highlyviscous binder.

The thermoplastic, high molecular weight polyester resin has a numberaverage Mn of at least 5,000, and in some embodiments the polyesterresins have a Mn of at least 10,000. The polyesters may bebiodegradable, and/or may contain renewable components. In oneembodiment, the polyester comprises at least 50% by weight of renewablecomponents. In another embodiment, the polyester comprises greater than80% by weight of renewable components. In yet another embodiment, thepolyester comprises essentially 100% by weight of renewable components(Example 4).

In one embodiment, the polyesters may comprise aliphatic diacid andaliphatic diol components. Although a wide range of aliphatic diacidsand aliphatic diols may be used, it is preferred that these componentscome from renewable sources. Renewable aliphatic diacid and aliphaticdiol components may include but are not limited to Bio-PDO(1,3-propanediol), 1,4-butanediol, sebacic acid, succinic acid, adipicacid, azelaic acid, glycerin, and citric acid.

The polyesters may be pre-reacted with epoxidized natural oils, or thereaction can occur during the melt processing into layers. Such reactionduring melt processing is a type of dynamic vulcanization. Dynamicvulcanization is the process of intimate melt mixing of two or morereactive components, such as an acid-terminated polyester and epoxidizednatural oil, and the reaction occurs between at least two of thesecomponents during the melt mixing.

Other diacid and diol components from renewable resources will becomeavailable as the need for renewable materials continues to grow. Thediol components may also include diols which are branched or hindered tolimit crystallinity in the final polyester binder. These can includeneopentyl glycol, glycerin, and others.

Renewable components based on plants, animals, or biomass processes havea different radioactive C¹⁴ signature than those produced frompetroleum. These renewable, biobased materials have carbon that comesfrom contemporary (non-fossil) biological sources. A more detaileddescription of biobased materials is described in a paper by RamaniNarayan, “Biobased & Biodegradable Polymer Materials: Rationale,Drivers, and Technology Exemplars”, presented at American ChemicalSociety Symposium, San Diego 2005; American Chemical Society Publication#939, June 2006. The Biobased Content is defined as the amount ofbiobased carbon in the material or product as fraction weight (mass) orpercent weight (mass) of the total organic carbon in the material orproduct. ASTM D6866 (2005) describes a test method for determiningBiobased Content.

Theoretical Biobased Content was calculated for the resultant polyesterresins in Table 2 and Table 3. In one embodiment the Biobased Content isat least 5% by weight. In another embodiment the Biobased Content is atleast 50% by weight. In still another embodiment the Biobased Content isat least 80% by weight.

In another embodiment, the thermoplastic, high molecular weightpolyesters or the highly viscous polyesters can comprise aromatic diacidcomponents and aliphatic diol components. The aromatic acid componentsmay include but are not limited to phthalic acid (anhydride),isophthalic, or terephthalic acids. In some cases an amount oftrimellitic anhydride can also be used.

In another embodiment, the thermoplastic, high molecular weightpolyesters may comprise aliphatic diacid and aromatic diacid componentsreacted with various aliphatic diols.

The thermoplastic, high molecular weight polyesters may also bebranched. For example utilizing aliphatic alcohols that have more thantwo functional groups, such as glycerin, or aromatic acids having morethan two functional groups such as trimellitic anhydride may be used toproduce branched polyesters.

Although, the above diacid components are described, it is understoodthat their simple diesters such as from methanol or ethanol can be usedto prepare the thermoplastic, high molecular weight polyesters or highlyviscous polyesters via known transesterification techniques.

Depending upon the diacid and diol selected, polyesters can be amorphousor crystalline/semi-crystalline materials. In one embodiment, thepolyester is amorphous. Table 2 shows some examples of amorphouspolyester binders of the invention and their weight % renewablecomponents.

TABLE 2 Compositions of Amorphous Polyesters With Renewable Content Ex-1Ex-2 Ex-3 Ex-4 Ex-5 Ex-6 Trade Name Amt (g) Amt (g) Amt (g) Amt (g) Amt(g) Amt (g) 1,3-Propanediol 367.60 380.88 381.80 372.21 370.19 357.65Isophthalic acid 545.99 232.94 233.50 292.68 291.08 218.72 Phthalicanhydride 85.90 385.69 208.18 269.94 259.52 195.01 Adipic acid 0 0176.03 0 0 0 Azelaic acid 0 0 0 73.66 0 0 Sebacic acid 0 0 0 0 78.71228.13 Dibutytin bis-lauryl mercaptide 0.50 0.50 0.50 0.50 0.50 0.50(T-20) catalyst Biobased Content wt % 27 27 47 34 36 53 Wt % RenewableContent 37 38 56 45 45 59 Tg Differential Scanning 25° C. 3° C. −22° C.−9° C. −10° C. −29° C. Calorimetry (DSC)

In another embodiment, the polyester is crystalline and comprises a Tgbelow about 25° C. and a crystalline melting temperature Tm greater thanabout 25° C. In yet another embodiment, the polyester has a Tg at orbelow about 25° C. and a Tm between about 25° C. and about 200° C. Table3 shows some examples of polyesters having a Tg at or below about 25° C.and Tm above about 25° C. Tg and Tm were determined by standardDifferential Scanning Calorimetry (DSC) techniques. The polyestercompositions include modifying 100% renewable aliphatic polyesters bythe addition of an amount of aromatic diacid, such as terephthalic acid,to help control crystalline regions and Tm.

TABLE 3 Compositions of Crystalline Polyesters With Renewable ContentIngredient Ex-7 Ex-8 Ex-9 Ex-10 Ex-11 Ex-12 Ex-13 Glycerin 25 24Phthalic anhydride 62 67 387 1,3-Propanediol 510 238 138 258 241 228 334Trimellitic anhydride 122 Sebacic acid 1130 281 538 Isophthalic acid 765Terephthalic acid 232 231 394 425 110 1,6-Hexanediol 156 T-20 Catalyst3.8 1.8 1.5 1.5 1.5 1.8 0.5 Tg ° C. −21 −35 7 25 22 −41 2 Tm ° C. 122125 135 197 77 40 141 Wt % Renewable Content 88 69 18 34 32 85 33 ofstarting material Biobased Content wt % 85 67 13 27 26 87 27

The high molecular weight polyesters may be prepared by several knownmethods. One method involves esterification of a diacid and a diolcomponents at elevated temperature. Typically, a slight excess of diolis employed (see Procedure 1). After the acid functional groups haveessentially reacted, a high vacuum is applied and excess diol isstripped off during transesterification, thereby increasing molecularweight. In some embodiments, 1,3-PDO is the diol of choice to build highmolecular weight in this step of the process.

It has been found that high molecular weight polyester resin can be madeby esterification of a diacid and diol at elevated temperature using avery slight excess of diacid (See Procedure 1B). After all the hydroxylgroups are reacted, a high vacuum is applied to build molecular weight.The mechanism by which high molecular weight is achieved is not clear.Table 4 shows some examples of polyesters comprising renewablecomponents and the number average molecular weights obtained from theseprocesses of Procedure 1.

Another method for obtaining high molecular weight polyesters involvesthe co-reaction of a renewable polyester with recycle polyesters such asPET (polyethylene terephthalate), PBT (polybutylene terephthalate), PPT(polypropylene terephthalate) or other recycle polyester resins. Inthese co-reactions an aliphatic polyester comprising renewableingredients was first prepared as described in Procedure 1. The recyclepolyester resin was then mixed with the aliphatic polyester andtransesterification between the two polyesters was accomplished at hightemperature and preferably under high vacuum. In one embodiment, theco-reacted polyester had a Tm at or below about 150.degree. C. thatcould be processed in low intensity mixers. See Example 2.

TABLE 4 High Molecular Weight Polyester Compositions Having RenewableContent Ingredient Ex-14 Ex-7 Ex-12 Ex-15 Ex-16 Ex-17 Ex-18 Glycerin 2524 1.53 1.53 Phthalic anhydride 159 133 4 91 1,3-Propanediol 212 510 228199 38 44 310 Trimellitic anhydride Sebacic acid 84 1130 538 155 40 5187 Isophthalic acid 416 347 508 Terephthalic acid 232 110 50 42Neopentyl glycol 124 2 Cyclohexane dimethanol 161 1,6-Hexanediol 9 T-20Catalyst 5 3.8 1.8 5 0.4 0.4 5 Molecular Weight Mn 16,900 15,900 10,4008,000 8,490 7,530 7,000

Molecular weight of the polyester resins was determined by GelPermeation Chromatography (GPC) using the following procedure. Thepolyester resin was dissolved into tetrahydrofuran (THF), quantitativelydiluting to about 30 mg/ml and filtering with a 0.45 micron filter. Twodrops of toluene were added to each sample solution as an internal flowrate marker.

Samples soluble in THF were run by the following conditions. GPCanalysis was run on the TriSec instrument using a four column bank ofcolumns with pore sizes: 10⁶, 2 mixed D PLGel and 500 Angstroms. Threeinjections were made for the sample and calibration standards forstatistical purposes. Universal Calibration (UC) GPC was used todetermine MW. UC is a GPC technique that combines Refractive Index (RI)detection (conventional GPC) with Intrinsic Viscometry (IV) detection.Advantages of UC over conventional GPC are:

1. MW is absolute (not relative only to standards).

2. Yields information about branching of molecules.

The mobile phase for the THF soluble samples was THF at 1.0 ml/min. Thedata was processed using the Viscotek OmniSec UC software. Theinstrument is calibrated using a series of polystyrene narrow standards.To verify calibration, secondary standards were run. They include a250,000 MW polystyrene broad standard, and a 90,000 MW PVC resin. Thecalculated molecular weight averages are defined as follows:

$M_{n} = \frac{\sum\left( {Area}_{i} \right)}{\sum{\left( {Area}_{i} \right)/\left( M_{i} \right)}}$$M_{w} = \frac{\sum\left\lbrack {\left( {Area}_{i} \right) \times \left( M_{i} \right)} \right\rbrack}{\sum\left( {Area}_{i} \right)}$$M_{z} = \frac{\sum\left\lbrack {\left( {Area}_{i} \right)^{2} \times \left( M_{i} \right)} \right\rbrack}{\sum\left\lbrack {\left( {Area}_{i} \right) \times \left( M_{i} \right)} \right.}$

-   Area=The area of the i^(th) slice of polymer distribution-   M_(i)=The molecular weight of the i^(th) slice of polymer    distribution-   Polydispersity (Pd)=a number value used to describe the molecular    weight distribution and is obtained by M_(w)/M_(n).

Highly crystalline or some high molecular weight samples insoluble inTHF were dissolved in a 50/50 (wt.) mixture of tetrachloroethylene(TTCE)/phenol. The column set is 10⁴ and 500 Angstrom 50 cm Jordicolumns. The mobile phase was 50/50 (wt.) mixture of TTCE/phenol at 0.3ml/min. flow rate. The slower flow rate is due to the greater backpressure of the solvent system on the columns. The data was processedusing the Viscotek UC OmniSec software.

Since MW data must be compared from one column set to the other,standards and selected samples were run on both column sets in THF forcomparison. A calibration curve was made for each column set. There isgood agreement of the standards between the two sets.

Products may be prepared by combining the homopolymer PVC resin and highmolecular weight polyester resin or highly viscous polyester resin andheating to melt mix the resins and other formulation ingredients. Themelt mixed formulation can then be formed into layers to createstructures using processing methods known in the art, including but notlimited to calendaring, extruding, casting, consolidating, andlaminating. In some structures the layer may be homogeneous, and filledor unfilled depending upon its location and function within thestructure. In other cases, the melt mixed formulation can be formed intochips or particles. These chips or particles can be further processed inmany different ways to provide products. For example, they can be usedto prepare layers comprising consolidated ships or particles, as knownin commercial sheet and tile product structures.

The examples described below describe the formation of tile productsutilizing traditional low intensity, “dough type” mixers. It isunderstood that the homo-polymer PVC and high molecular weightpolyesters or highly viscous polyesters may be mixed using highintensity, “extruder type” mixers to process the formulations intoproducts. The examples described below describe the formation of VinylComposition Tile (VCT) type products, but are not intended to limit thescope of the invention to these type products. The binder systemcomprising homo-polymer PVC resin and high molecular weight polyesterresin or highly viscous polyester resin eliminates the need forco-polymer PVC resins, and low molecular weight, volatile plasticizersin these structures.

Procedure 1 Procedure for Preparation of High Molecular WeightPolyesters from Diacids and Diols

1A: This describes the general procedure utilized to make thermoplastic,high molecular weight polyesters from diacids and diols. A desiredpolyester formulation was developed based upon mole equivalent weight ofthe diacid and diol functional groups. An excess of diol of the mostvolatile diol component of the formulation was employed in theformulation. In one embodiment, 1,3-propanediol was the excess diol ofchoice. The diacid and diol ingredients were added into a stainlesssteel vessel of a RC1 automated reactor (Mettler-Toledo Inc, 1900Polaris Parkway, Columbus, Ohio), stirred and heated under a continuousflow of pure, dry nitrogen. Typically, the ingredients were heated to200° C. for 2 hours and temperature increased to 230° C. for anadditional 4 to 6 hours until essentially all acid end groups werereacted and theoretical amount of water removed. Subsequently, thenitrogen was stopped and a high vacuum was applied. The mixture was heatand stirred under high vacuum for an additional 4 or more hours at 230°C. to 300° C. In some cases the temperature of the transesterificationstep was increased to 250° C. or higher. Depending upon the experiment,a vacuum in the range of 5 mm of mercury was utilized. Subsequently, thepolymer was allowed to cool to 150° C. to 200° C. and physically removedfrom the reactor under a flow of nitrogen and allowed to cool to roomtemperature.

It is understood that removal of the volatile diol component duringtransesterification leads to high molecular weight. High molecularweight may be obtained faster if higher vacuum is utilized (below 1 mmof mercury). It is also known that as the melt viscosity increases dueto increased molecular weight, the removal of diol becomes moredifficult. The increase in molecular weight can become diffusiondependent because of the high viscosity of the molten polyester. Thismeans that the released volatile diol from the transesterificationreaction reacts back into the polymer before it can diffuse out of themelt, and be removed. Renewing the surface of the melt can facilitatethe loss of diol and increase molecular weight. The polyesters obtainedby this procedure generally have terminal hydroxyl end groups.

Although, diacid components are described above, it is understood thattheir simple diesters such as from methanol or ethanol can be used toprepare the thermoplastic polyester resin via known transesterificationtechniques. The polyesters from this procedure generally have esterterminated end groups.

1B: The same general procedure as in 1A is employed. A desired polyesterformulation was developed based upon mole equivalent weight of thediacid and diol functional groups. An excess of about 0.01 to 0.5 moleexcess of diacid was typically employed in the formulation. Theingredients were mixed and heated as in 1A above, except that thetemperature was generally held below 200° C. to keep acid/anhydride frombeing removed until all hydroxyl groups were reacted. Subsequently, ahigh vacuum was applied as in 1A and the mixture heated to between 230°C. and 280° C. and stirred as in Procedure 1A. The resultant highmolecular weight polyester was removed from the reactor and cooled as in1A.

The mechanism of achieving high molecular weight is not clear. In someformulations containing phthalic anhydride, the phthalic anhydride wasidentified as being removed from the mixture under high vacuum.

Tables 5A to 5E provide additional examples of high molecular weightpolyesters having renewable components made according to the procedureof Procedure 1.

TABLE 5A Raw Material Ex-19 Ex-20 Ex-21 Ex-22 Ex-23 Ex-24 Ingredient Amt(g) Amt (g) Amt (g) Amt (g) Amt (g) Amt (g) 1,3- 380.88 383.65 378.15382.15 384.72 375.80 Propanediol Isophthalic acid 232.94 167.59 297.34210.34 164.70 206.85 Phthalic 385.69 448.26 324.01 348.28 272.71 342.49anhydride Trimellitic 0.00 0.00 0.00 0.00 0.00 0.00 anhydride Adipicacid 0 0 0 58.73 173.38 0.00 Azelaic acid 0 0 0 0 0 74.37 T-20 0.50 0.500.50 0.50 0.50 0.50 Tg (° C.) −1° C. −5° C. 22° C. −11° C. −23° C. 4° C.

TABLE 5B Raw Material Ex-25 Ex-26 Ex-27 Ex-28 Ingredient Amt (g) Amt (g)Amt (g) Amt (g) 1,3-Propanediol 366.04 373.73 360.20 261.06 Neopentylglycol 0 0 0 112.82 Isophthalic acid 156.70 205.71 154.20 294.12Phthalic anhydride 259.46 340.60 255.33 112.38 Azelaic acid 217 0 0 0Sebacic acid 0 79.47 229.77 219.12 T-20 0.50 0.50 0.50 0.50 Tg (° C.)−12° C −12° C −29° C −21° C

TABLE 5C Ex-29 Ex-30 Ex-31 Ex-32 Ex-33 Ex-34 Ex-35 Ex-36 Ingredient Amt(g) Amt (g) Amt (g) Amt (g) Amt (g) Amt (g) Amt (g) Amt (g)1,3-Propanediol 185.83 180.60 293.74 302.88 283.02 285.36 268.32 262.57Neopentyl glycol 108.93 105.92 0 0 0 0 0 0 Isophthalic acid 365.30276.13 288.72 231.54 278.18 218.15 263.73 200.73 Phthalic anhydride268.82 231.12 257.41 206.44 248.01 194.49 235.14 178.96 Succinic acid 00 159.63 258.64 0 0 0 0 Adipic acid 0 0 0 0 190.29 301.51 0 0 Azelaicacid 0 0 0 0 0 0 232.31 357.24 Sebacic acid 70.56 205.73 0 0 0 0 0 0T-20 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50

TABLE 5D Ex-2 Ex-37 Ex-38 Ex-3 Ex-4 Ex-39 Ingredient Amt (g) Amt (g) Amt(g) Amt (g) Amt (g) Amt (g) 1,3- 380.88 363.80 378.45 381.80 372.21363.39 Propanediol Isophthalic acid 232.94 635.70 297.58 233.50 292.68222.24 Phthalic 385.69 0 265.31 208.18 260.94 198.14 anhydride Adipicacid 0 0 58.16 176.03 0 0 Azelaic acid 0 0 0 0 73.66 215.74 T-20 0.500.50 0.50 0.50 0.50 0.50

TABLE 5E Ex-5 Ex-6 Ex-40 Ex-41 Ex-41 Ingredient Amt (g) Amt (g) Amt (g)Amt (g) Amt (g) 1,3-Propanediol 370.19 357.65 0 269.12 261.06 1,6Hexanediol 0 0 590.32 0 0 Neopentyl glycol 0 0 0 116.30 112.82Isophthalic acid 291.08 218.72 0 389.83 294.12 Phthalic anhydride 0 0252.26 0 0 Trimellitic anhydride 0 0 252.26 0 0 Sebacic acid 78.71228.13 0 75.30 219.12 T-20 0.50 0.50 0 0.50 0.50

EXAMPLE 2

Preparation of High Molecular Weight Polyesters by Co-Reaction withRecycle Crystalline Polyesters

The following formulation was processed as per Procedure 1 to preparethe aliphatic polyester EX-43 comprising 100% renewable components and aBiobased Content of 100%.

EX-43 1,4-Butanediol 400.5 Sebacic acid 600 T-20 Catalyst 0.4

The aliphatic polyester EX-43 was mixed with PET bottle recycle resinobtained from Nicos Polymers & Grinding of Nazareth, Pa., and catalystadded as listed below.

EX-44 Amt (g) PET recycle bottle 100 EX-43 100 T-20 Catalyst 0.13

The mixture was heated under nitrogen at 265° C. for a period of about 3hours, and a high vacuum applied as in Procedure 1 for an additional 3hours at 265° C. Subsequently, the resultant polyester having 50% byweight of renewable content and 50% by weight of recycle content wasshown to have a Mn of 17,200 with a Tg of −9° C. and a Tm of 114° C. Mnof the starting PET recycle bottle resin was determined by GPCtechniques described above and found to be 14,000. A sample of PET filmobtained from Nicos Polymers & Grinding was also analyzed by GPC and Mndetermined to be 17,300.

EXAMPLE 3

Examples of Polyesters made by Transesterification between HighMolecular Weight Aliphatic, Renewable Polyesters and Recycle PolyesterResin

High molecular weight polyesters comprising the compositions of Table 6Awere made according to Procedure 1.

TABLE 6A Azelaic Acid 1,4-Butanediol Sebacic Acid T-20 Total Amt (g) Amt(g) Amt (g) Amt (g) Amt (g) Ex-45 511 489 0.4 1000 Ex-46 582 417.6 0.41000 Ex-47 400.5 600 0.4 1001 Ex-48 471.2 528 0.4 1000 Ex-43 674 325.740.5 1000 Ex-49 354 529 0.4 883

The polyesters of Table 6A, were each mixed with recycle PET bottleresin obtained from Nicos Polymers & Grinding of Nazareth, Pa., and 0.1%T-20 catalyst added and transesterification conducted as per Example 2.In some examples, transesterification was also carried out on PBT resinCelanex 1600A obtained from Ticona (formerly Hoechst Celanese Corp.),Summit, N.J. Table 6B shows some of the resultant polyester co-reactionproducts and their Tm. It is obvious that these transesterificationreactions may be carried out on virgin PET or PBT type resin.

TABLE 6B melt Mid- Polyester range point PE ID used Recycled (° C.) mpTransesterification in Transesterification Bottle PBT PB Ecoflex PBtrans (Tm) Rxn # Rxn PET Celanex Azelate FBX7011 Sebacate product ° C.Nicos Scrap 255-259 256 PET Ex-50 Ex-45 70 30 138-154 145 Ex-51 Ex-46 5050  84.5-104.8 94.9 Ex-52 Ex-46 70 30 140-159 146 Ex-53 Ex-47 50 50 99-126 102.9 Ex-54 Ex-47 70 30 155-170 160 Ex-55 Ex-48 50 50 101-125109 Ex-56 Ex-48 70 30 149-156 151 Ex-57 Ex-43 50 50 100-111 105 Ex-58Ex-43 70 30 133-141 136 Ex-59 Ex-49 50 50  92-106 97 Ex-60 Ex-49 70 30110-170 140 Ex-61 Ex-45 75 75 135-141 137 Ex-62 Ex-49 75 75 145-166 156Ex-63 Ex-47 180 120  79-153 87 Ex-64 Ex-43 180 120  73-108 79 Ex-65Ecoflex 180 120 122-158 137 FXB7011

The melting points listed in Table 6B were determined using an“Optimelt” automated unit. Higher Tm co-reacted polyesters may beproduced by using less aliphatic polyester than described in the Table6B above.

EXAMPLE 4

Preparation of Vinyl Composition Type Tile having a Binder ComprisingPVC Homo-Polymer Resin and Highly Viscous Polyester Resin

This is an example of VCT flooring product prepared with a bindercomprising homopolymer PVC and an amorphous, thermoplastic, highmolecular weight polyester resin. The following VCT formulation,comprising homopolymer PVC and high molecular weight polyester resinEx-6 of Table 2, was mixed using a low intensity Baker Perkins heatedmixer. The ingredients were added to the mixer which was heated to 325°F. The formulation was mixed and heated for approximately 7 to 11minutes in the Baker Perkins mixer to a drop temperature ofapproximately 280° F. Depending upon the formulation, mixing time variedbetween 4 to 16 minutes on average and drop temperature varied betweenapproximately 280° F. and 290° F.

The hot, mixed formulation was then dropped into the nip of a two rollcalendar. The rolls of the calendar were set a differenttemperatures—one roll hotter than the other. Typically, the hot roll wasset at about 290° F. and the cold roll set at about 250° F. The nipopening between the calendar rolls were set to provide a final sheetthickness of about 125 mils. The processability of the formulations wereevaluated using the key described in Table 7A. As can be seen from theformulation and processing data sheet Table 7B, the formulation basedupon homopolymer PVC and the high molecular weight polyester or highlyviscous polyester processed very similar to a standard PVC formulationcontaining PVC copolymer and low molecular weight plasticizer.

TABLE 7A Key for Baker Perkins and Mill Evaluations Mix Appearance 1.very soft, wet, flowable mix 2. tough mix, dough like 3. soft mix, smallbeads 4. dry mix with some clumps 5. very dry powdery mix, no clumps 6.unmelted pellets/polyester Sheet Appearance 1. soft flexible sheet 2.smooth sheet 3. cracks in sheet and/or voids 4. ragged edges, unevensheet thickness, wavy 5. lots of folds from being taken off with theblade Sheet Hot Strength 1. falls apart when removed from roll, powder2. falls apart when removed from roll, small pieces or partial sheet 3.full sheet which falls apart under sheet weight 4. no stretch undersheet weight 5. slight stretch under sheet weight 6. sheet shrinks whenpulled off the mill Roll Tack 1. sticks to a roll, all can't be removedwith the blade 2. sticks to a roll, removed with the blade but notcleanly (chatter marks) 3. sticks to a roll, removed cleanly with theblade 4. material split between two rolls 5. material does not stick toeither roll Roll Residue 1. a lot 2. a little 3. none Self Feeding 1.yes 2. marginal 3. no

TABLE 7B Formulation And Processing Data Sheet PVC Control EX-79Ingredient Amt (g) Amt (g) PVC Homopolymer 104.49 104.49 PVC Copolymer34.83 0 Phthalic Plasticizer 48.43 0 Ca Stabilizer 2.76 2.78 Filler(Limestone) 1012.21 1012.21 Pigment (TiO2) 7.48 7.26 EX-6 0 83.26 Total1210 1210 Wt % Filled 84.25% 84.25% Mixer Temp ° F. 324 327 Batch Time(min) 11-32  7-11 Mix Drop Temp ° F. 280-284 276-283 East Roll SetPressure psi 70 72 West Roll Set Pressure psi 24 28 East Roll Temp ° F.290 288 West Roll Temp ° F. 245 255 Gap Setting 2.09 2.09 SheetThickness 122-125 122-125 Mix Appearance 4 4, 2 Sheet Appearance 2 2Sheet Hot Strength 4 4 Roll Tack 3 3 Roll Residue 3 3 Self Feeding 1 1

The final calendered sheet was removed from the calendar and cut intotile and physical properties determined. The tile comprising PVChomo-polymer and highly viscous polyester binder met the VCT ASTM 1066standards for indentation, static load and impact resistance.

EXAMPLE 5 Preparation of Vinyl Composition Type Tile Having a BinderComprising PVC Homo-Polymer Resin and Thermoplastic, High MolecularWeight Polyester Resin

This is an example of a flooring product having a binder comprisinghomopolymer PVC resin and a totally aliphatic, thermoplastic, highmolecular weight polyester resin. The following formulation wasprocessed as per Procedure 1 to prepare the aliphatic polyester EX-80comprising 100% renewable components. The polyester had a Tg of −16° C.and a Tm of 62° C.

Trade Name EX-80 Azelaic acid 510.8 1,4, Butanediol 489 Dibutyltinbis-lauryl mercaptide 0.40

The following VCT formulation, comprising homopolymer PVC and highmolecular weight polyester resin EX-80 was mixed using a low intensityBaker Perkins heated mixer as described in Example 4. The followingformulation and processing data sheet Table 7 documents that theformulation processed acceptably. The final calendered sheet was removedfrom the calendar and cut into tile and physical properties determined.The Tile comprising PVC homo-polymer and thermoplastic, high molecularweight polyester EX-80 binder met the VCT ASTM 1066 standards forindentation.

TABLE 8 Formulation And Processing Data Sheet EX-81 Ingredient Amt (g)PVC Homopolymer 94.985 Ca Stabilizer 2.53 Filler (Limestone) 920.194Pigment (TiO2) 6.6 Polyester EX-80 76 Total 1100 Wt % Filled 84.2 EastMixer Temp ° F. 324 West Mixer Temp ° F. 325 Batch Time (min) 13 MixDrop Temp ° F. 282 East Roll Set Pressure psi 72 West Roll Set Pressurepsi 24 East Roll Temp ° F. 289 West Roll Temp ° F. 250 Gap Setting 2.01Sheet Thickness 125 Mix Appearance 3 Sheet Appearance 2 Sheet HotStrength 4 Roll Tack 3 Roll Residue 3 Self Feeding 2

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A product, comprising: a biobased component;wherein the biobased component includes recycle polyester resin.
 2. Theproduct of claim 1, wherein the recycle polyester resin includespolyethylene terephthalate, polybutylene terephthalate, or polypropyleneterephthalate.
 3. The product of claim 1, wherein the recycle polyesterresin has a biobased content of at least about 5% by weight.
 4. Theproduct of claim 1, wherein the recycle polyester resin has a biobasedcontent of at least about 50% by weight.
 5. The product of claim 1,wherein the recycle polyester resin has a biobased content of at leastabout 80% by weight.
 6. The product of claim 1, wherein the recyclepolyester resin includes at least 98% by weight of recycle components.7. The product of claim 1, wherein the recycle polyester resin includesan aromatic diacid component.
 8. The product of claim 7, wherein therecycle polyester resin includes a second aromatic diacid component. 9.The product of claim 1, wherein the recycle polyester resin includes analiphatic diacid component.
 10. The product of claim 1, wherein therecycle polyester resin includes an aliphatic diol component.
 11. Theproduct of claim 1, wherein the recycle polyester resin includes analiphatic polyester component.
 12. The product of claim 1, wherein therecycle polyester resin is hydroxy terminated.
 13. The product of claim1, wherein the recycle polyester resin is acid terminated.
 14. Theproduct of claim 1, wherein the recycle polyester resin includes anaromatic diacid component and an aliphatic diacid component.
 15. Theproduct of claim 1, wherein the biobased component includes recyclethermoset resin based fillers.
 16. The product of claim 15, wherein therecycle thermoset resin based fillers include urea formaldehyde andrubber materials.
 17. The product of claim 1, wherein the biobasedcomponent includes inorganic biobased filler.
 18. The product of claim1, wherein the product qualifies for at least one point under the LEEDrating system.
 19. A flooring product, comprising: a biobased component;wherein the biobased component includes a polyester resin; wherein thepolyester resin is the co-reaction product of an aliphatic polyestercomprising a renewable component and a recycle polyester resin; whereinthe polyester resin is aromatic based and includes polyethyleneterephthalate, polybutylene terephthalate, or polypropyleneterephthalate; and wherein the polyester resin has a biobased content ofat least about 5% by weight.
 20. A composition, comprising: a filler;and a polymeric binder blended with the filler; wherein the fillerincludes inorganic biobased filler or recycle thermoset resin basedfiller; wherein the polymeric binder includes a biobased component;wherein the biobased component includes recycle polyester resin; andwherein the polyester resin has a biobased content of at least about 5%by weight.